Curved wall and ceiling frame member and method and apparatus for producing the same

ABSTRACT

Method and apparatus for producing a predetermining curvature in the flange and web of a structural member including an indexing mechanism and method for controlling the amount of curvature produced.

BACKGROUND OF THE INVENTION

[0001] It has been a difficult and time-consuming problem to produce curved frame members to define curved stud wall and ceiling constructions. This has been done in the past by cutting short segments of sheetmetal frame members and attaching these segments to a plywood base panel at the top and bottom of a wall or ends of a ceiling section to define the desired curved configuration. The segments define the desired wall or ceiling curvature and suitably spaced studs are fixed at their ends to the segments to define the prescribed curvature of the wall or ceiling construction.

[0002] Another prior art solution has been developed which provides top and bottom wall channels in which the flanges of the channels are formed from a plurality of spaced apart tabs formed by outwardly divergent cut-out notches made in the flanges. The web of the channel between the flanges can then be bent to form the prescribed radius of curvature of the wall and the tabs can be nailed to a plywood backing plate to define the desired curved wall structure. The upper and lower ends of the wall studs are anchored to the curved channels to provide the desired curved wall support structure. This product has been sold in the marketplace under the trademark “Flexi Wall”. This “Flexi Wall” product requires that the prescribed curvature of the top and bottom channels to be laid out on the floor and ceiling to define the curved wall.

SUMMARY OF THE INVENTION

[0003] The present invention provides a method and apparatus for producing metal channels which are formed into a prescribed curved shape while maintaining the structural integrity of the channel members. No sheetmetal or plywood anchoring plates are required for this construction. The invention includes a device for producing the desired curvature in wall or ceiling channels which support the ends of the members extending between the channels.

[0004] The apparatus for producing the curvature includes a die punch for punching out a series of relief holes and indenting dies for indenting both the web and flange portions of the channels. These holes and indentations produce the prescribed curvature in the channels and the apparatus can be easily adjusted to vary the radius of curvature according to the architect's design. The apparatus may also include a die for punching out relief holes in the web of the channels.

[0005] The method for producing the curved channels includes indenting the web and the adjacent flange portion to produce the desired curvature in the channel member. The method may also include punching out relief apertures in the channel web.

[0006] The prescribed curved channel is produced by a series of cutouts and indentations formed in the flange end and web of the channel. The cut-outs and indentations are spaced apart a calculated distance to produce the prescribed curvature which may be varied by adjusting the depth and frequency of the indentations formed.

DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a perspective view showing the spaced indentations and notches formed in a curved channel member embodying the invention;

[0008]FIG. 2a is a perspective view of a curved wall section;

[0009]FIG. 2b is a perspective view of a curved ceiling section;

[0010]FIG. 3a is a perspective view of apparatus embodying this invention;

[0011]FIG. 3b is another perspective view of the apparatus shown in FIG. 3a but showing a typical channel member in bending position;

[0012]FIG. 4a is an end view showing the flange indenting apparatus in raised position;

[0013]FIG. 4b is an end view thereof in partially operative position;

[0014]FIG. 4c is a view thereof in final flange indenting position;

[0015]FIG. 5 is a top plan view of the flange indenting die;

[0016]FIG. 6 is a side elevational view of the mechanism shown in FIG. 5;

[0017]FIG. 7 is a front elevational view of the mechanism shown in FIGS. 5 and 6;

[0018]FIG. 8 is a fragmentary perspective view showing the flange indenting mechanism;

[0019]FIG. 9a is perspective view of one side of the web piercing mechanism and the adjustment apparatus therefor;

[0020]FIG. 9b is a perspective view of the other side thereof; and

[0021]FIG. 10 is an end view of the mechanism shown in FIGS. 9a and 9 b.

[0022]FIG. 11 is a perspective view of an alternative form of the invention;

[0023]FIG. 12 is a cross section of the structure shown in FIG. 13;

[0024]FIG. 13 is a perspective view thereof;

[0025]FIG. 14 is fragmentary section;

[0026]FIG. 15 is a perspective view of the rear portion of the device.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0027] The apparatus includes a base 10 for supporting the operating mechanism which is mounted on a suitable bench (not shown). The base 10 has platform 10 a with a channel-positioning guide track 10 b for receiving and guiding a channel member 25 to be curved. A pair of upstanding support brackets 11 are fixed to the base 10 and a shaft 12 is journaled for rotation on the upper ends of said brackets 11 as by suitable support pins 12 a. The shaft is parallel to the track and has an operating handle 14 fixed thereto to provide rotary oscillation of the shaft 12 as will be further described. In the form shown, the shaft 12 is of square cross-sectional shape.

[0028] As best shown in FIGS. 3a and 3 b, a pair of spaced cross rails 15 form cross track 15 a as a part of the base 10. A pair of connected spaced apart oscillating arms 16 are pivoted at the back portion of the cross rails 15 as by bushings 16 a and a suitable pivot pin 16 b mounted therein. A pair of connecting arms 17 are fixed to the operating handle 14 as best shown in FIGS. 3a and b and 4 a, b and c. The oscillating arms 16 are provided with generally arcuately shaped upper slot segments 16 c and lower slot segments 16 d. A roller shaft 17 a is mounted at the rear end portion of arms 17 and rides in the slot segments 16 c and 16 d. A spring clip 17 b is mounted on the base 10 and engages the shaft 17 a to releasably hold the handle 14 in raised position.

[0029] As best shown in FIGS. 5-7, a flange indenting blade 18 is mounted for sliding movement in a guiding trackway formed in a guide block 20 which is fixed to cross track 15 a. The guide block 20 has a guide pin 21 fixed thereto and forms a guide for the indenting blade 18 as well as for the channel member 25 being curved. The blade 18 has an elongated guiding slot 18 a formed therein and the guide pin 21 slides in the slot 18 a. A confining cap 20 b is fixed to the forward end of the top of indenting blade 18 and, during the crimping operation, engages and confines the indentation 25 b being formed in the flange 25 a of the channel member 25 being curved. The cap 20 b also serves as a guide for the web indenting blade 28 during actuation thereof.

[0030] As best shown in FIG. 8, the rear end of the indenting blade 18 is connected to a drive shaft 24 which connects the blade to the double actuating arms 26 which are pivoted at their lower ends to the stationary cross shaft 16 b. The arms 26 are actuated by the handle 14 which is connected thereto by a link 27 and pins 26 a and 27 a as best shown in FIGS. 4a and 4 b.

[0031] As best shown in FIGS. 4a and 4 b, a front clamping block 30 is slidably mounted in the cross track 15 a formed by the spaced cross rails 15 of the platform 10. A downwardly extending actuating portion 30 a of the clamping block 30 is connected by an adjustable link 31 to downwardly extending portions 16 e of the oscillating arms 16, so that movement of the arms 16, by handle 14, will pull the front clamping block 30 back into backup engagement with the flange 25 a of channel 25 positioned in the guide track 10 b as best shown in FIG. 4a.

[0032] As best shown in FIGS. 4a-4 c, a web indenting die arm 28 is pivoted at its forward end on pivot pin 28 a mounted on upstanding support post members 29 fixed to the front of platform 10 as best shown in FIGS. 3b and 4 a-4 c. A roller 28 b is journaled on the upper rear end of the arm 28 and is engaged by the bottom surface of the handle 14 during the final stages of the downward operating movement of the handle. A mounting pin 28 c has a spring 28 d mounted thereon. The spring resiliently urges the indenting arm 28 upwardly into the retracted position.

[0033] An adjustment mechanism controls the depth of the indentations 25 b and 25 c formed in the channel member 25 as best shown in FIG. 1. As best shown in FIGS. 9a and 9 b, this adjustment mechanism is mounted on the operating shaft 12. These adjustments are made by limiting the increments of rotational movement the operating shaft 12. This adjustment mechanism includes a sleeve 35 mounted for rotational adjustment on the shaft 12 as best shown in FIGS. 9a, 9 b and FIG. 10. A pair of mounting arms 36 are fixed to the sleeve 35 and include a pair of adjustment indicator scales 36 b located at the outer ends of the arms 36. Each of these indicator scales 42 a and 42 b provides a reference for each specific bending job being run. Operational rotation of the operating shaft 12 is limited by the engagement of the bottom edges 36 a of the mounting arms 36 with the top edge of rear track element 10 b of the base platform 10. The indentations 25 b and 25 c in the channel 25 produce the curvature in the channel and the depth and spacing of the indentations controls the amount of curvature produced. The adjusted angular position of the arms 36 on the cross shaft 12 controls the increment of rotational movement of the shaft 12 produced by downward actuation of the handle 14. This angular relationship between the shaft 12 and the arms 36 is adjusted for each job by a clamping screw 38 which extends through an arcuate slot 35 a in the sleeve 35 as best shown in FIGS. 9a and 9 b. A mounting bar 39 is fixed to one side of the square operating shaft 12 by screws 39 a and underlies the sleeve 35 and extends along the shaft 12 beyond the ends of the sleeve 35.

[0034] A piercing die 40 is mounted on the arms 36, as best shown in FIGS. 3b, 9 a and 10, and produces a pierced opening 25 d in the top web of the channel 25 as indicated by the cut out segment 25 e as shown in FIGS. 10 and 3b. This opening 25 d provides a visual locator index for the operator to hand-position the channel section 25 on the track 10 b. Indexing arms 41 a and 41 b are welded to the bar 39 which is fixed to the operating shaft 12 by bolts 39 a, as best shown in FIGS. 9a and 9 b. An indexing scale 36 b is provided on the free ends of the arms 36 to provide a reading which indicates the desired radius of curvature of the channel 25 being bent according to the architect's specifications. The arms 41 a and 41 b are fixed at their rear portions to the operating shaft 12 and are provided with a pair of indexing segments 42 a and 42 b respectively connected at their forward ends to the arms 41 a and 41 b, as best shown in FIG. 9a. The relationship between the arms 41 a and 41 b and the mounting arms 36 is adjustable by a screw knob 45 which is rotatably mounted in a cross bar 46 connected to the arms 41 a and 41 b. The lower end of the adjusting shaft 47 fixed to the knob 45 is threadably connected to a second cross bar 48 which in turn is connected to the arms 36 as best shown on FIGS. 9a and 9 b. It will be seen that rotation of the knob 45 and shaft 47 will cause the relationship between the arms 41 a and 41 b and the die mounting arms 36 to be adjusted, thus adjusting the depth of the indentations 25 b and 25 c being produced by the indenting dies 18 and 28. Suitable tapped holes 12 b are made in the shaft 12 as best shown in FIGS. 9a and 9 b to provide selected locations for the sleeve 35 and arms 36 and web piercing die 40 on the shaft 12. The lower end of the clamping screw 38 engages the surface of the back side of square shaft 12 and locks the sleeve 35 in the desired longitudinal position on shaft 12 to position the piercing die 40. The arms 36 “bottom out” against the top surface of the back rail of the track 10 b to govern the depth of the indentations 25 b and 25 c and thus control the exact radius of curvature of the channel 25 and facilitate easy adjustment of this radius.

[0035] As best shown on FIG. 9, an indicator 50 is provided which engages the top of the channel being curved and indicates to the operator that the preset indenting stroke of the operating handle has “bottomed out” so that the operator will discontinue his downward pressure on the operating arm for that particular indenting sequence. The indicator 50 can be in a number of different forms in that it can take the form of a positive stop element as shown in the accompanying drawing or it can take the form of an indicator light which would tell the operator that he has completed that particular indentation operation.

[0036] An alternative construction illustrated in FIGS. 11 through 14 which is an improvement in some of the apparatus disclosed in my presently pending application for U.S. Letters Patent, Ser. No. 08/831,404, filed in the U.S. Patent Office on Apr. 1, 1997 and entitled CURVED WALL AND CEILING FRAME MEMBER AND METHOD AND APPARATUS FOR PRODUCING THE SAME. This improved apparatus includes a supporting base 10 which is adapted to be mounted on a suitable supporting structure (not shown). A guide track 10 b is supported on a base 10 and is adapted to receive a channel member to be curved. A pair of spaced apart upstanding support brackets 11 are fixed to the base 10 and a cylindrical shaft 12 is journaled for rotation between the upper ends of said support brackets 11 as by suitable support pins 12 a. An operating handle 14 is fixed to the shaft 12 and is adapted to removably receive a handle extension 14 a (not shown) to permit manual rotary operation of the shaft 12.

[0037] As best shown on FIG. 12, the platform 10 a is provided with an opening 15 b and a pair of oscillating arms 16 are pivoted on a pivot pin 16 b mounted at the rear of the platform 10 a. A pair of connecting arms 17 are integrally formed with the operating handle 14 as best shown in FIGS. 11 and 13. The oscillating arms 16 are provided with arcuately shaped upper slot segments 16 c and lower slot segments 16 d. A roller shaft 17 a is mounted at the rear end portion of arms 17 and rides in the slot segments 16 c and 16 d. The arms 17 are integrally formed with the operating handle 14 as best shown in FIGS. 11 and 13.

[0038] A flange indenting blade 18 is mounted for sliding movement in a guiding trackway formed in a guide block 20 which is fixed to cross track 15 a formed in the cross rail 15. The guide block 20 has a guide pin 21 fixed thereto and forms a guide for the indenting blade 18 as well as for the channel member 25 being curved. The blade 18 has an elongated guiding slot 18 formed therein and the guide pin 21 slides in the slot 18 a. A confining cap 20 b is fixed to the forward end of the top of indenting blade 18 and, during the crimping operation, engages and confines the indentation 25 b being formed in the flange 25 a of the channel member 25 being curved. The cap 20 b also serves as a guide for the web indenting blade 18 during actuation thereof.

[0039] The rear end of the indenting blade 18 is connected to a drive shaft 24 which connects the blade to the double actuating arms 26 which are pivoted at their lower ends to the stationary cross shaft 16 b. The arms are actuated by the handle 14 which is connected thereto by a link 27 and pins 26 a and 27 a.

[0040] A front clamping block 30 is slidably mounted in the cross track 15 a formed by the spaced cross rails 15 of the platform 10. A downwardly extending actuating portion 30 a of the clamping block 30 is connected by an adjustable link 31 at pivot point 30 a to downwardly extending portions 16 e of the oscillating arms 16, so that movement of the arms 16, by handle 14, will pull the front clamping block 30 back into backup engagement with the flange 25 a of channel 25 positioned in the guide track 10 c.

[0041] A web indenting die arm 28 is pivoted at its forward end on pivot pin 28 a mounted on upstanding support post members 29 fixed to the front of the platform 10. A roller 28 b is journaled on the upper rear end of the arm 28 and is engaged by the bottom surface of the handle 14 during the final stages of the downward operating movement of the handle. A mounting pin 28 c has a spring 28 d mounted thereon. The spring resiliently urges cam 28 e of the indenting arm 28 upwardly into retracted position when the handle 14 is in the raised position.

[0042] An adjustment mechanism controls the depth of the indentations formed in the channel member 25. This adjustment mechanism is mounted on the operating shaft 12. These adjustments are made by limiting the increments of rotational movement of the operating shaft 12. This adjustment mechanism includes a sleeve 35 mounted for rotational adjustment on the shaft 12, as best shown on FIG. 1. The sleeve 35 is restrained against longitudinal movement on the shaft 12 by support bracket 11 on one end and handle 14 on the other end. A pair of mounting arms 36 are fixed to the sleeve 35 and include a pair of adjustment indicator scales 42 a and 42 b located at the outer ends of the arms 26. Each of these indicator scales 42 a and 42 b mounted on surface 36 b provides a reference for each specific bending job being run. Operational rotation of the operating shaft 12 is limited by the engagement of the bottom edges of arms 36 with the top surface of channel web 25 being curved. The indentations 25 b and 25 c in the channel 25 produce the curvature in the channel and the depth and spacing of the indentations controls the amount of curvature produced. The adjusted angular position of the arms 36 on the sleeve 35 controls the increment of rotational movement of the shaft 12 produced by the downward actuation of the handle 14. This angular relationship between the shaft 12 and the sleeve 35 and arms 36 is adjusted for each job.

[0043] An indexing scale 36 b is provided on the free ends of the arms 36 to provide a reading which indicates the desired radius of curvature of the channel 25 being bent according to the architect's specifications.

[0044] As best shown in FIG. 14, the relationship between the bracket 14 a and the mounting arms 36 is adjustable by a screw knob 45 which is rotatably mounted with a ball socket integral with bracket 14 a. The lower end of the adjusting shaft 47 fixed to the knob 45 is threadably connected to a cross bar 48 which in turn is connected to the arms 36 by pin 48 a shown on FIG. 14. It will be seen that rotation of the knob 45 and the shaft 47 will adjust the relationship between the bracket 14 a and the mounting arms 36. This adjusts the depth of the indentations 25 b and 25 c being produced in the channel 25 by the indenting dies 18 and 28. The arms 36 “bottom out” against the channel 25 being curved. This governs the depth of the indentations 25 b and 25 c and thus controls the exact radius of curvature of the channel 25 and facilitates easy adjustment of this radius. A mark 25 d on the channel member 25 provides a visual locator index for the operator to hand-position the channel section 25 on the track 10 b and produce the desired curvature in the channel. The clamping knob 45 a locks this shaft 47 in adjusted position.

[0045] As best shown in FIGS. 13 and 14, an indicator 50 is provided which engages the top of the channel being curved and indicates to the operator that the preset indenting stroke of the operating handle has “bottomed out” so that the operator will discontinue his downward pressure on the operating arm for that particular indenting sequence. The indicator 50 can be in a number of different forms in that it can take the form of a positive stop element as shown in FIG. 14, or it can take the form of a torque indicator which would tell the operator that he has completed that particular indentation operation.

[0046] As shown in FIG. 11, the indicator rail 38 is fixed to sleeve 35. A marking die holder 39 is attached to the indicator rail 38 with bolts 39 a, and is positioned by the user in accordance with the prescribed spacing of the indentations. Marking die 40 is retained in holder 39 by set screw 40 a, and produces mark 25 b in the channel being curved at the end of each operation of the handle 14.

[0047] As best shown in FIG. 12, spring loaded balls 27 b were added to the handle mechanism and engage each side of link 27 at socket 27 c when the handle is rotated and retains the handle in full up position, which facilitates the positioning of the channel being curved. A cam 28 e has been added between spring 28 d and the indenting due arm 28. A pin 28 a is mounted to the post members 29 and adjusts the degree of rotation of cam 28 e, which facilitates the clearance required when advancing the channel being curved. A sleeve bearing 17 b is mounted on arm 17 and is concentric with roller shaft 17 a which increases the ease of rotation of the handle assembly. 

What is claimed is:
 1. Apparatus for producing a curved frame member for a curved wall or ceiling structure comprising means for supporting a member to be curved wherein said member includes a flange and a web portion, a flange indenting die for engaging and producing an indentation in said flange a web indenting die generally aligned with the flange indenting die to produce an indentation in the web in substantial registration with the indentation produced in the flange and thus produce a predetermined increment of curvature in the frame member, and means for moving the dies into and out of indenting position.
 2. Apparatus for producing a curved frame member of the type having a web and a flange for a curved wall or ceiling structure comprising a base, a work supporting platform mounted on the base and having a guide track for supporting and guiding an elongated frame member to be curved, a shaft generally parallel to the track and journaled on said base in spaced relation thereabove and having an operating handle fixed thereto to rotate said shaft, a flange indenting die connected with said handle for indenting a flange of a frame member supported on said track, a web indenting die aligned with the flange indenting die to produce an indentation in the web portion of the frame member adjacent to the flange indentation and aligned therewith to produce [the desired] a predetermined increment of curvature in the frame member.
 3. The structure set forth in claim 1 and a web piercing die operatively connected to said shaft for actuation thereby and aligned with the web of a channel supported on said base in predetermined spaced relation to the flange and web indenting dies to produce a web indexing cutout when the operating handle is actuated.
 4. The structure set forth in claim 1 and a backup die aligned with the flange indenting die to support the portion of the flange adjacent to the indentation thereof during the indenting operation.
 5. The method of producing a curved frame member for a wall or ceiling structure, said method comprising, initially supporting a member to be curved on a base member which includes spaced supporting elements, mounting a frame member to be curved on the platform, producing an indentation in the web of the member, and producing an indentation in the flange of the member compatible with the indentation of the web to produce a curvature in the member and limiting the indentation of the web and the flange to control the amount of curvature produced.
 6. The method for producing a predetermined curvature in a member having a web and flange, said method comprising, providing a web indenting head and a flange indenting head, actuating the heads to produce indentation in the web and flange of the member to be curved.
 7. The method set forth in claim 6 and adjusting the degree of indentation in the web and flange to vary the amount of curvature in the member being curved.
 8. A structural frame member for a curved wall and ceiling structural unit, said frame member comprising a web portion with a flange portion connected thereto, a generally triangular indentation formed in the web portion, an indentation formed in said flange portion and communicating with the indentation in the web portion to produce a shortening of the member on the flange portion thereof and thus produce a predetermined curvature in the member.
 9. The structure set forth in claim 8 and a cutout portion formed in said member adjacent the two indentations to facilitate the bending of the structure.
 10. The structure set forth in claim 8 and a plurality of said web and flange indentations to provide the desired curved structural member.
 11. A device for curving flanged members comprising a platform for supporting a flanged member to be curved, an elongated main cross shaft mounted on the platform for rotary oscillation, an operating handle connected with the cross shaft for producing rotary oscillation of the shaft, a flange indenting blade mounted for sliding movement on the platform transversely of the shaft, an actuating arm connected with the shaft to produce rotation thereof and also produce sliding movement of the blade into and out of indenting engagement with the flange of a member being curved, a web indenting die aligned with the flange indenting blade and having an actuating connection with the die when the handle is forcibly oscillated downwardly, an adjustment mechanism connected to the shaft and including a mounting arm assembly fixed to the shaft and positioned to engage the top surface of a flanged member being curved to control the indentation of the member and thus control the radius of curvature of the channel member.
 12. The structure set forth in claim 11 and a marking die holder connected to the main cross shaft for oscillation therewith and positioned to produce an indexing mark on the top surface of the flanged member being curved.
 13. The structure set forth in claim 11 and retaining means for releasably holding the handle in raised position but releasing the handle when downward pressure is exerted thereon. 